System and method for the automated assembly of trusses

ABSTRACT

The present invention relates to systems and methods used to assemble trusses composed of wooden components. The system comprises at least one station for cutting lumber into truss components (i.e., cords and web members), a station for position the cord members relative to one another, a station for positioning the web member relative to the cord members for attachment, and a station for securing the web members to the cord members and/or other web members in a predetermined sequence.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. §119(e)(1) of the Jan.23, 2007, filing date of U.S. Provisional Application No. 60/886,147,the entirety of which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

This invention relates to systems and methods used to assemble trusses.More specifically, the present pertains to the automated assembly oftrusses composed of wooden components.

A typical truss 10 fabricated from wooden components is illustrated inFIG. 1, and includes cord members 11A, 11B that form a perimeter of thetruss 10, and web members 12 disposed between and secured to the cordmembers 11A, 11B. Although some stages of the fabrication of trusses maybe automated, the overall process remains labor intensive. In thefabrication of the truss 10, raw material, i.e., uncut lumbercomponents, are cut to desired lengths, and edges of the components aretrimmed for assembly. Automated saw systems are used to cut the trusscomponents, including the cord members 11A, 11B and web members 12. Sucha saw system is disclosed in U.S. application Ser. No. 11/096,634. Thelinear movement of the lumber through a cutting path, and the vertical,rotational and linear movement of a saw is automated and governed by acontroller, which may include a computer with one or more processors anda database.

In larger manufacturing facilities, the specifications of the trusses tobe manufactured are entered into the controller of the saw systemincluding data such as the total number of trusses, the total number ofeach truss component, the length of each component and the angle of theends of the components. The controller may be programmed to cut all thecomponents of a single truss or component by component. In such a casethe components are bundled then taken to an assembly station where thetrusses are manually assembled. First, the cord members 11A, 11B areassembled to form the perimeter. Thereafter, the web members 12 arepositioned between the cord members 11 and secured thereto in order fromleft to right, or from right to left. These steps take a considerableamount of manpower and time. Presently, there does not exist a system ormethod for the automated assembly of a truss.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of a truss as is known in the art;

FIG. 2 is a top schematic view of a system for the automated assembly ofa truss;

FIG. 3 is a perspective view of an assembly table with the cord memberspositioned for assembly;

FIG. 4 is a perspective view of vector cams mounted for movement on anassembly table;

FIG. 5 is a perspective view of a vector cam having a register androllers;

FIG. 6 is an exploded view of a vector cam and the components thereof;

FIG. 7 is a perspective view of a vector cam positioned adjacent theapex of the truss.

FIG. 8 is a perspective view of the vector cam of FIG. 7 repositioned toengage the truss on the other side of the apex of the truss.

FIG. 9 is a perspective view of the vector cam of FIG. 7 engaging thetruss on the other side of the apex of the truss.

FIG. 10 is a top schematic view of cord members entering the assemblyarea of the assembly table.

FIG. 11 is a top schematic view of clamping devices engaging andadvancing cord members on the assembly table.

FIG. 12 is a top schematic view of an assembly table with the clampingdevices and roller guides repositioning the cord members on the assemblytable.

FIG. 13 is another top schematic view of an assembly table with theroller guides repositioning the cord members on the assembly table.

FIG. 14 is a perspective view of an automated press for affixingconnector plates to cord members and web members of the truss;

FIG. 15 is an front plan view of the automated press alignment systemshowing the automated press mounted on an overhead rail for back andforth movement of the automated press;

FIG. 16 is a front plan view of the automated press showing the upperand lower platen sections with panels removed;

FIG. 17 is a perspective view of a robotic arm retrieving connectorplates from a plate bin adjacent an automated press;

FIG. 18 is a perspective view of the robotic arm of FIG. 17 moving twoconnector plates from the plate bin to the automated press;

FIG. 19 is a rear perspective view of a base portion of a compartment ofa plate bin;

FIG. 20 is a cross-sectional view of a compartment of the plate binshowing the pushing assembly for pushing connector plates from thecentral column to the front cavity;

FIG. 21 is a front perspective view of a base portion of a compartmentof a plate bin;

FIG. 22 is a front perspective view of a base portion of a compartmentof a plate bin showing connector plates in a central column and an emptyfront tray;

FIG. 23 is a front perspective view of a base portion of a compartmentof a plate bin showing connector plates in a front tray;

FIG. 24 is a perspective view of a web presenter picking up a web memberfrom a web conveyor;

FIG. 25 is a perspective view of a web presenter characterizing an endsection of a web member through a sensor mounted on a vertical post;

FIG. 26 is a perspective view of a web presenter placing thecharacterized web member on an assembly table for pickup by a mainrobotic arm;

FIG. 27 is a plan view showing the board to be characterized by sensorsmounted on vertical posts;

FIG. 28 is a plan view showing the determination of the leftmost pointor edge of a web member by a vertical post having a sensor;

FIG. 29 is an exploded plan view of the left sensor detecting theleftmost point or edge of a web member;

FIG. 30 is an exploded plan view of the left sensor detecting a secondleading edge of a web member;

FIG. 31 is a plan view showing the determination of a rightmost point oredge of a web member by a vertical post having a sensor;

FIG. 32 is an exploded plan view of the right sensor detecting therightmost point or edge of a web member;

FIG. 33 is an exploded plan view of the right sensor detecting a secondleading edge of a web member;

FIG. 34 is a plan view of a web member showing the location of measuredpoints on the web member;

FIG. 35 is a top plan view showing a robotic aim placing a web member inbetween cord members in accordance with one aspect of the presentinvention;

FIG. 36 is a perspective view of a main robotic arm having clampingmembers and staple guns; and

FIG. 37 is a perspective view of a large gantry press for securingconnector plates to a truss.

DETAILED DESCRIPTION OF THE INVENTION

The features of the invention believed to be novel are specifically setforth in the appended claims. However, the invention itself, both as toits structure and method of operation, may best be understood byreferring to the following description and accompanying drawings.

Exemplary embodiments of the present invention solves the problems inthe art by providing a system, method, and computer software code, forimproving operating capabilities of a automated truss assembly system.Persons skilled in the art will recognize that an apparatus, such as adata processing system, including a CPU, memory, I/O, program storage, aconnecting bus, and other appropriate components, could be programmed orotherwise designed to facilitate the practice of the method of anexemplary embodiment of the invention. Such a system would includeappropriate program means for executing the method.

An embodiment of the present invention for a system 13 and method forthe automated assembly of trusses is shown in the schematic of FIG. 2and includes a plurality of workstations. The system 13 comprises afirst station 14 that has one or more automated saw systems 17 forcutting truss components such as cord members 11A, 11B that make up aperimeter of a truss 10, and one or more automated saw systems 18 forcutting the web members 12 that are disposed between, and secured to thecord members 11A, 11B. A second station 15 includes an assembly table 20where the cord members 11A, 11B are staged or readied for assembly,positioned relative to one another for assembly of the truss 10, andthen secured to one another. In addition, at the second station 15 theweb members 12 are secured to the cord members 11A, 11B. A third station16 includes an automated system for presenting and positioning the webmembers 12 relative to the cord members 11A, 11B on the assembly table20 in order from left to right, or from right to left. The abovedescriptions and the dotted lines in FIG. 2 identifying differentworkstations are for purposes of example only, and are not intended tolimit the scope of the invention. In any of the embodiments describedherein, one or more workstations may be provided for assembling a trussin accordance with the present invention.

The system 13 is particularly useful in the assembly of large numbers oftrusses. For example, a single job may require the assembly of as manyas one hundred trusses or more. In such cases, the trusses are assembledin the order in which the trusses will be loaded onto a truck. In anembodiment, the system may include one or more of a plurality ofcontrollers. Each of the controllers are incorporated in the assemblysystem and are programmed with a specification to control the assemblyof a plurality of trusses. In addition, the controllers are programmedwith a specification to cut, stage and/or assemble a total number oftrusses 10 that includes a total number of cord members 11A, 11B and webmembers 12 to complete the job. Further, the controllers may beprogrammed to identify each truss 10, cord member 11 and/or each webmember 12 in the order in which they are to be cut and assembled and maymonitor the production of the trusses 10 so that one may determine thenumber of trusses 10 assembled at any time during production.

In an embodiment, the system includes eight controllers. Morespecifically, there are one or more controllers, such as controllers 28and 29, for the automated saw systems 17,18, a main controller 30, acontroller 31 for web presenter 90, controller 104 for the main roboticarm 101, controllers 41, 44 for the presses 71A, 71B. The databases ofcontrollers 28 and 29 include data relative to the dimensions of thetruss components including the length and width of a component, and theangle of cut to be made at either end of a component. The saw systems 17and 18, in response to appropriate input commands, cut the cord members11 and web members 12 respectively according to the entered data. It iscontemplated that communications delivered to any of the controllers ofthe system may be directed to the particular controller directly orindirectly through the main controller 30.

The database of main controller 30 in the second station 15 includes aspecification, including data, associated with the position of cordmembers 11A, 11B, i.e., the angle, relative to one another. In addition,the main controller 30 may include a specification, including data,relative to where a web member 12 is positioned on the truss 10including a point or points where a web member 12 is attached to cordmembers 11A, 11B and an angle at which a web member 12 is disposedrelative to the cord members 11A, 11B. The main controller 30 may belinked to any one or more of the other controllers by Ethernet or anyother suitable method of communication known in the art for providingcommunication between one or more of the other controllers to the maincontroller 30.

With respect to the embodiment shown in FIG. 2, the saw systems 17, 18are of the type disclosed in the patent application, U.S. applicationSer. No. 11/096,634 that was published on Oct. 5, 2006, U.S. Patent Pub.No. 2006/0219073 A1, the entirety of which is incorporated herein. Inaddition, the saw systems 17, 18 including the below described automatedfeeders, conveyors and roller tables are sold by TCT Manufacturing, Inc.located in Mount Dora Fla.

The saw systems 17, 18 include an entrance roller table 24 and an exitroller table 25 that have a plurality of rollers rotatably mounted on aframe. In this manner, a work piece such as a piece of lumber can belinearly fed into and out of a cutting zone in each of the saw systems17, 18. In the first station 14, pieces of lumber 23, 27 are placed onautomated feeders 22 and 26, which have a plurality of rotating belts orchains mounted to a frame and rotate in a direction perpendicular to thelinear movement of the lumber 23, 27 on the roller tables 24 of the sawsystems 17, 18 respectively.

The operation of the saw system 17 relative to the first station 14 andthe second station second 15, and components therefore, are nowdescribed in more detail. The saw system 17 is used to cut the cordmembers 11A, 11B. Pieces of lumber 23, taken from lumber carts 40 areplaced on the feeder 22, which transports the lumber to entrance rollertable 24 and into a cutting zone of the saw system 17. As describedabove, the controllers are programmed to generate a signal identifyingthe particular truss, i.e., the first truss, to be built, which trussincludes a predetermined number of top cord members 11A and apredetermined number of bottom cord members 11B. In addition, one ormore signals are generated that are indicative of the position of a sawblade (not shown) relative to the lumber; and, the saw system 17 cutsthe cord members 11A and 11B responsive to the signals and in accordancewith the data that represents the dimensions of a cord member 11A, 11B.

The example of the truss 10 shown in FIG. 1 has a triangular perimeterand includes two top cord members 11A and two bottom cord members 11B.However, the system 13 is not so limited and may be used to assembleother types of truss configurations including, but not limited to, arectangular truss wherein the top cord member 11A is positioned parallelrelative to a bottom cord member 11B.

In the embodiment described herein, the controllers are programmed sothe bottom cord members 11B are cut first before the top cord members11A are cut. However, the order in which the cord members 11A and 11Bmay depend on the location of the saws 17, 18 relative to the assemblytable 20. Indeed, as described in U.S. Provisional Application No.60/886,147, which is incorporated by reference herein, the top cordmembers are cut prior to the bottom cord members. After the lumber 23 iscut, the cord members 11A, 11B exit the cutting zone on the exitingroller tables 25 and are transported to the assembly table 20 viaconveyors 19A and 19B. Optionally, a splicer 32 may be positioned nextto the conveyor 19A to fasten the two bottom cord members 11B to oneanother and the top cord members 11A to one another for assembly of thetruss 10 in the second station 15. The fastening step is intended tomaintain the cord members 11A and cord members 11B in abuttingrelationship during assembly. In addition, the top cord members 11A aremoveable with respect to one another to form the apex 122 of the truss10. Connector plates 72, as will be described in more detail, arepressed onto the truss 10 later in the assembly process to affix thecord members 11A and 11B together.

Again with respect to FIG. 2, a plurality of transfer chains 33 areoperatively associated with the conveyor 19A and the assembly table 20to transfer the cord members 11A, 11B from the conveyor 19A to theassembly table 20. The transfer chains 33 may be characterized as acomponent of the first station 14 or second station 15. The operation ofthe transfer chains 33 with the conveyor systems is known to thoseskilled in the art and includes a chain or belt supported on a frame andone or more sprockets. The transfer chains 33 are disposed betweenspaced apart rollers (not shown) on the conveyor 19A and spaced apartrolling pins 36 on the assembly table 20. One or more hydraulically orpneumatically driven cylinder systems and servomotors (not shown),operatively connected to the controller 28 (and/or 30) and transferchains 33, control movement of the transfer chains 33 between a firstposition, below the conveyor 19A and assembly table 20, and a secondposition above the conveyor 19A and assembly table 20.

A sensor 35 is positioned toward an end of the conveyor 19A and is incommunication with a controller 28-30 and servomotors (not shown) todetect the presence of an approaching cord member 11A, 11B. Thecontrollers 28, 30 and/or sensor 35 have a processor (not shown) that isprogrammed to activate the servomotors and transfer chains 33 when acord member 11A, 11B is detected at a predetermined distance from thesensor 35 or an end of the conveyor 19A. The transfer chains 33 aredisposed in a first position below the conveyor 19A as the cord members11A, 11B travel along the conveyor 19A. When activated, the transferchains 33 are elevated between consecutive rollers on the conveyor 19A,engaging the cord members 11A and transferring the cord members 11A tothe assembly table 20.

With respect to the bottom cord members 11B, when the controller 28 or30 signals the transfer chains 33 to be elevated, the controller 28 or30 is programmed to maintain the transfer chains 33 in the second orelevated position a predetermined time which is sufficient for thebottom cord members 11B to travel along the transfer chains 33 until thebottom cord members 11B fall off the transfer chains 33 at apredetermined location of the assembly table 20. Alternatively, a secondsensor (not shown) is positioned on the assembly table 20 that detectsthe presence of the bottom cord member 11B and generates a signal. Thecontroller 28 or 30, in response to this signal and/or after apredetermined amount of time has elapsed, is programmed to lower thetransfer chains 33 to cause the bottom cord members 11B to fall off anend of the transfer chains 33 and onto the assembly table 20.

Similarly, with respect to the top cord members 11A, when the controller28 or 30 signals the transfer chains 33 to be elevated, the controller28 or 30 is programmed to maintain the transfer chains 33 in the secondor elevated position for a predetermined amount of time which issufficient for the top cord members 11A to travel along the transferchains 33 until the top cord members 11A fall off the transfer chains 33at a predetermined location of the assembly table 20. Alternatively, asecond sensor (not shown) is positioned on the assembly table 20 thatdetects the presence of the top cord member 11A and generates a signal.The controller 28, in response to this signal and/or after apredetermined amount of time has elapsed, is programmed to lower thetransfer chains 33 to cause the top cord members 11A to fall off an endof the transfer chains 33 and onto the assembly table 20.

The assembly of cord members 11A, 11B in the second station 15 isdescribed now in more detail. The top cord members 11A and bottom cordmembers 11B, as shown in FIGS. 3 and 10, are positioned on the assemblytable 20. In an embodiment, the assembly table 20 comprises theplurality of rolling pins 36 mounted on support members 37 (shown inFIG. 3) and spaced apart along the table 20. In the embodiment shown inFIG. 3, the rolling pins 36 are spaced apart on the table 20 and aredriven by a motor and belt assembly 38 to deliver the cord members 11A,11B along the assembly table 20. After the cord members 11A, 11B arepositioned on the table 20 as described above, the controller 30activates the one or more motors so the rolling pins 36 begin to rotateon the assembly table 20 to advance the cord members 11A, 11B toward theassembly area on the assembly table 20.

With respect to FIG. 10, the cord members 11A, 11B are spaced apart onthe assembly table 20 and aligned using vector cams 21A, 21B on theassembly table 20. When the cord members 11A, 11B advance on theassembly table 20, the vector cams (clamping devices) 21A, 21B androller guides 42A, 42B grip and/or engage the cord members 11A, 11B andadvance them on the assembly table 20 for assembly of the trussperimeter and truss 10.

A vector cam (clamping device) 21A or 21B is illustrated in more detailin FIGS. 4 and 6-8. Referring to FIG. 4, exemplary vector cams 21A arepositioned on the table 20 between consecutive spaced apart rolling pins36. The clamping devices 21A, 21B are mounted on, and moveable on tracks45 that are supported on a steel frame 46. The clamping devices 21A, 21Band roller guides 42A, 42B include a carriage 47 positioned in matingrelationship with the tracks 45. More specifically, the track 45 has agear-like configuration with consecutive teeth 59 and grooves 60. Wheels61 are mounted on axles 62 secured to the carriage 47 and are disposedin mating relationship with the track 45. The wheels 61 comprise spacedapart circular plates 63 with pins 64 disposed between the plates 63,which pins 64 are annularly spaced about the axle 62. The pins 64 arepositioned relative to the track 45 so that the pins 60 are in matingrelationship with the grooves on the track 45 so the carriage 47 movesas the wheels 61 rotate. In addition, the pins 64 preferably rotate sothat any sawdust generated during the assembly process will not collectin the grooves 60. Such a wheel and track assembly may be purchased fromthe Nexen Group, Inc. Vadnais Heights, Minn., for example.

As shown in FIG. 6, the back and forth movement of the carriages 47 iscontrolled in part by a servo-driver 65 operatively connected to thecontroller 30. The controller 30 identifies where the truss 10 is in theassembly process including the position of where the truss 10 is on thetable 20 and the orientation of the cord members 11A, 11B relative toone another. The controller 30 generates a signal that is representativeof a location (direction and distance) of where the carriage 47,including clamping mechanisms and/or rollers thereon, relative to an endof the track 45 and an angle at which the components (described below)are disposed relative to cord members 11A, 11B. Responsive to thissignal, the servo-driver 65 is activated to drive the carriage 47 apredetermined distance and direction on the track 45 and assembly table20.

Referring to FIG. 6, details of the vector cam 21A or 21B are disclosed.An arm 48 is mounted to an underside of the carriage 47 and supports thevector cams and rollers. More specifically, the vector cams 21A, 21Binclude a rotating register 49 and rollers 50 to engage, guide, moveand/or position the cord members 11A and 11B on the assembly table 20. Aservomotor 51 is operatively connected to the register 49 and isprogrammed via the controller 30 to rotate the register 49 inpredetermined increments to position cord members 11A and 11B on theassembly table 20 for receiving web members 12 at predeterminedlocations relative to the cord members 11A and 11B. The rollers 50 arepassive rollers and do not act to advance the cord members 11A, 11B, butserve as a guide maintaining the linear or angular position of the cordmembers 11A, 11B on the assembly table 20.

As is particularly shown in FIG. 6, the register 49 is mounted on ashaft 66 that is connected to the servomotor 51 for rotation of register49. The shaft 66 is inserted through a bearing 67 that is mounted to anend of the arm 48, and into the servomotor 51, which engages the shaft66. The mounting plate 52 that is fitted over the bearing 67 is mountedto an electric clutch 68 that is disposed between the bearing 67 andservomotor 51. When activated, the clutch 68 engages the servomotor 51so the plate 52 pivots in the same direction and at the same time theregister 49 rotates. When the clutch 68 is deactivated, the clutch 68disengages from the servomotor 51 and the register 49 continues torotate advancing a cord member 11A, 11B on the assembly table 20.

With respect to FIGS. 5-6, the rollers 50 (or position of the rollers50) are horizontally adjustable back and forth relative to the register49 and mounting plate 52. The vector cams 21A, 21B are equipped with apneumatic cylinder assembly including the block 53, piston 54 and guiderods 55 and operates to position the rollers 50 relative to register 49and cord members 11A or 11B. Such an assembly, and operation thereof, isknown to those skilled in the art. For example a company, Sintered MetalCorporation, located in Japan manufactures and sells such pneumaticcylinder assemblies. The position of the rollers 50 on the block 53 mayalso be manually adjusted. The block 53 has slots 69 in which adjustmentnuts (not shown), and bolts 70 securing the rollers 50 to the block 53in which the bolts 70 are threaded. The bolts 70 are simply loosenedwithin the nuts so the rollers 50 can slide back forth on the block 53.

As shown in FIG. 4, a cable carrier system 57 is supported on track beam58 mounted to the frame 46, and supports and protects cables or wiresconnecting the controller 30 to components of the vector cams 21A, 21B.An example of such a cable carrier system is sold under the brand nameIGUS®, which is sold by Igus, Inc. located in East Providence, N.J.

The roller guides 42A, 42B have similar components as theabove-described vector cams 21A, 21B. Accordingly, the description ofabove vector cams 21A, 21B applies to the roller guides 42A, 42B, withthe exception that the roller guides 42A, 42B do not include theregister 49 or the electric clutch 68. In addition, the rollers 50 onthe roller guides 42A, 42B are positioned on the cylinder block 53 toengage an outside edge of the cord members 11A, 11B, as shown in FIG. 3.The rollers 50 on the vector cams 21A, 21B engage an inside edge of thecord members 11A, 11B, and the register 49 engages the outside edge.

The operation of the vector cams 21A, 21B and roller guides 42A, 42B inpositioning the cord members 11A and 11B on the assembly table 20 is nowdiscussed in more detail in reference to FIGS. 3 and 10-13. In theembodiment shown in FIG. 3, the system 13 includes four vector cams 21A,21B (two each for the top cord members 11A and bottom cord members 11Brespectively) and four roller guides 42A, 42B (two each for the top cordmembers 11A and bottom cord members 11B). However, the system 13 maycontain more or fewer of each of the vector cams 21A, 21B and rollerguides 42A, 42B.

At the outset, when the entire system 13 is started to assemble trusses10, each of the controllers 28, 29, 30 is programmed to identify eachtruss component used to assemble a truss 10, and each truss 10 that hasbeen assembled. Accordingly, as the cord members 11A and 11B are stagedon the assembly table 20 as described above, the vector cams 21A, 21Bare aligned with the cord members 11A, 11B for receiving cord members11A, 11B as the rolling pins 36 advance the boards.

With respect to FIG. 10, the vector cams 21A, 21B are illustrated in anopen position with the pneumatic cylinder assembly biasing the passiverollers 50 away from the register 49. Each of the four vector cams 21A,21B is equipped with a sensor 56, such as a through-beam sensor or alimit switch, to detect the presence of a cord member 11A or 11B. Whenthe sensor 56 detects the cord member 11A or 11B, the controller 30generates a signal in response to which the vector cam 21A, 21B closesagainst the cord member 11A or 11B as shown in FIG. 11.

In an embodiment of the invention, the bottom cord member 11B isadvanced along the assembly table 20 before the top cord member 11A,because the angle at which the top cord member 11A is positionedrelative to the bottom cord member 11B, and the position of the vectorcams 21A and roller guides 42A on the track is based on a point oforigin 113 taken from an edge of the bottom cord member 11B as shown inFIG. 10. A through beam sensor 110 is mounted to the assembly table 20between the vector cams 21A, 21B and roller guides 42A, 42B. When thethrough beam sensor 110 detects the presence of the bottom cord member11B, a signal is sent to controller 30 that generates a signalresponsive to which the registers 49 stop rotating. The registers 49then reverse their rotation to back the bottom cord member 11B apredetermined distance.

The top cord members 11A are then advanced so the registers 49 on thevector cams 21A, 21B begin rotating. With respect to FIG. 1, the truss10 has a triangular configuration, so the position of the top cordmembers 11A relative to one another and relative to the bottom cordmembers 11B is adjusted to form the triangle. The controller 30 isprogrammed to identify the particular truss 10 being assembled and thecontroller 30 includes a database that includes data representative ofthe dimensions of the truss member 10, including but not limited to theangles at which the top cord members 11A are disposed relative to oneanother and relative to bottom cord members 11B.

When the sensor 56 (through-beam sensor) detects the presence of the topcord member 11A, a signal is generated and sent to the controller 30,which identifies the board as a top cord member 11A. The controller 30generates one or more signals in response to which the registers 49 stoprotating and reverse rotation to back the top cord member 11A apredetermined distance. In addition, the one or more signals areindicative of a position/angle of each vector cam 21A on the assemblytable 20 relative to a position the top cord members 11A. Responsive tothese signals, the mounting plate 52 and rollers 50 on vector cams 21Aand roller guides 42A pivot with respect to the arm 48 to position thetop cord member 11A at a predetermined angle with respect to the bottomcord member 11B. As shown in FIGS. 12-13, the vector cams 21A and rollerguides 42A move on the track 45 in the direction indicated by arrows Ato account for the angled position of the top cord member 11A.

In addition, as shown in FIG. 13, the mounting plate 52 and rollers 50on the roller guides 42A rotate with respect to arm 48 to apredetermined angle relative to the bottom cord member 11B. As the topcord member 11A advances on the table 20, the roller guides 42A engagethe top cord member 11A to maintain the top cord member 11A in positionrelative to the other cord members 11A, 11B and web members 12 as thetruss 10 is assembled. Similarly, the roller guides 42B are positionedto engage the bottom cord member 11B; however, typically the bottom cordmember 11B is disposed substantially horizontally. Therefore, themounting plate 52 and rollers 50 are not pivoted to a predeterminedangle as roller guides 42A.

As mentioned above the controller 30 is programmed to identify eachtruss 10 that is being assembled including identifying each cord member11A, 11B and web member 12 that is used in the assembly process. To thatend, the controller 30 includes data that represents particular tasksthat must be performed and the order in which such tasks must beperformed. In addition, the controller 30 records the performance ofeach task.

The data input into the controller 30 or recorded by the controller 30also includes data representative of where the truss components 11A, 11Band 12 are to be positioned relative to one another (and/or relative tothe point of origin 113 as referred to herein) and/or relative to one ormore reference points on the assembly table 20. In addition, the dataalso includes data relative to the position of the system componentssuch as the vector cams 21A, 21B, guide rollers 42A, 42B, presses 71(described below) and robotic stable guns 230 (described below) or othercomponents, relative to the truss components 11A, 11B and 12, and/orrelative to one or more reference points on the assembly table 20.Accordingly, the controller 30 is programmed to generate signalsrepresentative of the position of the system components on the assemblytable 20 necessary to perform a particular task. Once that task isperformed, the controller 30 generates signals necessary to repositioncertain components as necessary to perform a subsequent task.

By way of example, and in reference to FIG. 10, once the top cord member11A is positioned at a predetermined angle relative to the bottom cordmember 11B, the controller 30 generates signals that are representativeof a predetermined distance that the corner (or point of origin 113) ofthe truss 10 must be advanced on the table 20. After the truss 10 isadvanced, robotic staple guns 230, which are explained in detail furtherbelow and are shown in FIG. 36, for example, are positioned on the table20 to staple the corners of the top cord member 11A and bottom cordmembers 11B together.

After the components 11A, 11B are stapled together, the truss 10 isadvanced on the table a predetermined distance where a press 71A, 71B(described below) is positioned to attach connector plates 72 to thecorner of the truss 10. After the connector plates 72 are affixed to thecorner of the truss 10, the truss 10 is advanced a predetermineddistance so a web member 12, as shown in FIG. 38, may be positionedbetween and stapled to cord members 11A and 11B. After this task isperformed, the truss 10 is advanced a predetermined distance to aposition on the assembly table 20 where the presses 71A, 71B arepositioned to affix connector plates 72 to the web member 12 and cordmembers 11A, 11B, thereby securing the web member 12 in place.

As the truss 10 advances on the table 20, the roller guides 42A andvector cams 21A are repositioned on the table 20 to maintain the topcord member 11A in its predetermined position relative to the bottomcord member 11B. As shown in FIG. 7, the vector cam 21A, for example,will eventually reach an apex 122 of the truss 10 wherein the vector cam21A or roller guide 42A is positioned on a first top cord member 11A′,and must be repositioned to engage a second top cord member 11A″.

As shown in FIG. 8, responsive to one or more signals from controller30, the vector cam 21A opens and disengages the first cord member 11A′.The arm 48 then pivots downward removing the register 49 and rollers 50from the path of travel of the truss 10. In this way, the arm 48 ismovable from a first position where the register 49 and/or plurality ofrollers 50 engage a cord member to a second position where the register49 and/or plurality of rollers 50 do not engage the cord member 11A″.The truss 10 then advances on the table 20 so the vector cam 21A willengage the second top cord member 11A″. The mounting plate 52, register49, and rollers 50 pivot with respect to the arm 48 (eithersimultaneously with or after the arm 48 pivots downward) to the sameangle the cord member 11A″ is disposed relative to the bottom cordmember 11B.

As shown in FIG. 9, the arm 48 is then pivoted upward such that therollers 50 and the register 49 engage the second top cord member 11A″.When activated, the rollers 50 will rotate to advance the truss 10 onthe table 20. It is contemplated that as the apex 122 moves down theassembly table, the remaining vector cams 21A, 21B and roller guides42A, 42B will undergo similar repositioning as described with respect toFIGS. 7-9.

Operation of Presses to Affix Connector Plates to the Truss

In connection with the assembly of trusses using the present system, anautomated press 71 is provided that moves back and forth on the assemblytable 20 to affix connector plates 72 to the truss 10 to secure the webmembers 12 to cord members 11A, 11B or to affix cord members 11A and/or11B to one another. With respect to FIG. 14, there is illustrated anembodiment of an automated press 71 for use in the assembly of a truss10. An embodiment of the invention may include two presses 71A and 71Bon opposed sides of the assembly table 20 to affix connector plates 72as needed to any truss 10. In one embodiment, the press 71A affixesconnector plates 72 to top cord members 11A and web members 12 and thepress 71B affixes connector plates 72 to the bottom cord members 11B andweb members 12 as shown in FIG. 2.

As shown in FIG. 14, exemplary press 71A includes an upper or top platen73 that is supported on a press frame 74 and spaced above a lower orbottom platen 75 supported on the press frame 74. Both the top platen 73and bottom platen 75 may include a magnet or are otherwise magnetizedfor engaging and installing the connector plates 72 on a truss 10. Inaddition, both the upper platen 73 and the lower platen 75 areconfigured for movement relative to one another.

As shown in FIG. 14, and in detail in FIG. 16, each of the upper platen73 and the lower platen 75 are welded to a post 76 that is housed insidea spring 78. The posts 76 and springs 78 are operatively connected to apneumatic cylinder 80 for raising or lowering either one of the upperplaten 73 and lower platen 75 with respect to the other of the upperplaten 73 and lower platen 75. Pneumatic cylinder 80 includes acompressed air source (not shown) and a piston 83 for driving the upperplaten 75 downward toward lower platen 73 or lower platen 73 upwardtoward upper platen 75. Springs 78 allow the upper platen 75 or lowerplaten 73 to return to a home or resting position after the platens 73,75 affix web members 12 to cord members 11A, 1B as described below. Thepneumatic cylinder 80 may be used to separate the connector plates 72when two connector plates are placed on the lower platen 73 or to aid inretracting the platens 73, 75 after the connector plates 72 are pressedonto a particular truss 10. Additionally, the presses 71A, 71B mayinclude one or more hydraulic cylinders as are known in the art forproviding the pressing force needed to press connector plates 72 andaffix connector plates 72 to the truss 10 to secure the web members 12to the cord members 11A, 11B or cord members 11A and/or 11B to oneanother.

In addition, the presses 71A, 71B are mounted for back and forth lateralmovement on an overhead rail 124 for positioning the presses 71A, 71Brelative to a truss 10 to attach connector plates 72 to the truss 10.The presses 71A, 71B are mounted on the overhead rail 124 and thepresses 71A, 71B are positioned adjacent the assembly table 20. Toenable lateral movement of the presses 71A, 71B on overhead rail 124,presses 71A, 71B each include a press alignment system 126.

As shown in FIG. 14, and more particularly in FIG. 15, the pressalignment system 126 includes opposed upper frame portions 128, whichmay be C-shaped members 129 as shown and connected to the frame 74 ofthe press 71A or 71B. Each upper frame portion 128 or C-shaped member129 includes a disc 130 mounted by a shaft 132 to opposed plates 133 onopposed sides of the C-shaped member 129. The disc 130 includes anannular groove 138 that extends around a circumference of the disc andis rotatably maintained on the overhead rail 124 on a lower track 140 onI-beam member 144. As shown in FIGS. 14-15 by exemplary press 71B, thepresses 71A, 71B may include a plurality of C-shaped members having adisc 130, shaft 132, and plates 133 to enable smooth back and forthmovement of the presses 71A, 71B on I-beam member 144.

In addition, each upper frame portion 128 includes a servo-driver 146for driving the disc 130 and presses 71A, 71B forward and backward onoverhead rail 124 as described below. Specifically, servo-driver 146includes a rotating spindle 148 and a wheel 149. The wheel 149 hashaving a plurality of spaced apart circular plates 151 with pins 150disposed between the plates 151 that engages a track 158 (similar totrack 45) that extends longitudinally adjacent a center of the I-beammember 144.

As shown in FIG. 14, to enable overhead movement of the presses 71A, 71Bon overhead rail 124, overhead rail 124 includes the I-beam member 144mentioned above that has a center wall 152 for dividing the I-beammember 144 into a left side 154 and a right side 156. Each of the leftside 154 and right side 156 includes the track 158 that has a gear-likeconfiguration with consecutive teeth 160 and grooves 162 and a lowertrack 140 for rotatably mounting disc 130. Driven by the servo-driver146, the pins 150 of the wheel 149 are adapted to mate with the teeth160 and grooves 162 of the track 158 to move the presses 71A, 71Blaterally backward and forward on the I-beam member 144 along with thesimultaneous directional rotation and movement of disc 130. The presses71A, 71B can be moved back and forth to be in position to affixconnector plates 72 to permanently attach web members 12 to cord members11A, 11B.

The back and forth movement of the press 71, lateral movement of thebottom platen 75, and vertical (up/down) movement of the top platens 73is triggered by trip switches in communication with the servo-driver146, pneumatic cylinders, and controllers 30, 41, or 44 that control ormanage movement of the presses 71A, 71B and press components. Thecontroller 30 identifies where the truss 10 is in the assembly processincluding the position of where the truss 10 is on the table 20. Morespecifically, the controller 30 has a database having data stored thatis representative the number of each size connector plate 72 to beplaced on a given truss 10 and the location of where each connectorplate 72 is positioned on each truss 10.

As described in more detail below, two robotic arms 85, each disposedadjacent a respective press 71A, 71B transfers connector plates 72 froma bin assembly 86 to the presses 71A, 71B for installation. The roboticarm 85 is mounted on a base 87 and takes connector plates 72 from thebin assembly 86 as shown in FIG. 17 and rotates to move the connectorplates 72 toward top platen 73 and bottom platen 75 of the press 71A.Specifically, the robotic arm 85 will first move the connector plates 72to the lower platen 75 of the press 71. When the press 71 is ready toreceive connector plates 72 for installation on a truss 10, the roboticarm 85 has a magnet 88 for engaging connector plates 72 in the binassembly 86. Typically, the robotic arm 85 takes two connector plates72, including a top connector plate 72A and a bottom connector plate72B, and positions the connector plates 72A, 72B on the bottom platen75, with the bottom connector plate 72B magnetically engaged on thebottom platen 75. One suitable source for a robotic arm 85 of the typedescribed herein, which may be modified as desired, is the Fanuc RobotLR MATE 200ib robotic arm.

Subsequently, the top platen 73 lowers and engages the top connectorplate 72A and then the top platen 73 is raised holding the top connectorplate 72A spaced above the second connector plate 72B, which remains onthe bottom platen 75. The controller 30, 41, or 44 then generates asignal that is indicative of a location on the truss 10 where theconnector plates 72A, 72B are to be affixed to the truss 10, or thesignal may be indicative of the distance the press 71A or 71B musttravel on the overhead rail 124. Responsive to this signal, theservo-driver 146 drives the press 71A, 71B into position for attachmentof the connector plates 72A to the truss 10. The top platen 73 andbottom platen 75 stamp the connector plates 72A, 72B into place on thetruss 10.

The balance springs 78 may be positioned on the press 71A to support thebottom platen 75 such that when the top platen 73 is lowered, thesprings 78 adjust the bottom platen 75 upward to engage the trusscomponents. In this manner, the truss components are not depresseddownward below a plane of the assembly table 20 when the press 71installs the connector plates 72, which may cause the truss componentsto misalign. After installing the connector plates 72A, 72B, the press71 returns to a position adjacent to the robotic arm 85 for receivingtwo more connectors 72A, 72B. The robotic arm 85, and associatedhardware and software that can perform the functions as describedherein, are commercially available through ABB Robotics and/or NachiRobotics, model number VSO5E/LE-02.

These robotics contain programmable controllers and processors thatcontrol movement of the arm. The main controller 30 is linked to therobotic arm 85 to generate a signal indicative of an instruction for therobotic arm 85 to retrieve a connector plate 72 from the bin assembly86. The controller 30, includes a database that represents the totalnumber of connector plates 72 used to complete a particular jobincluding the total number of each size connector plate 72, the order inwhich each connector plate 72 shall be retrieved from the bin assembly86 and the coordinates (x,y,z) at which each connector plate 72 islocated relative to an end of the robotic arm 85 and the ground. Thecontroller 30 indexes or counts the connector plates 72 as they areretrieved from the bin assembly 86 in order to identify the subsequentplates 72 to be retrieved. The assembly of a truss 10 typically requiresseveral different sizes of connector plates 72. For example, the smallerconnector plates 72 may range in size from 3″×4″ to 6″×6″. Accordingly,several bins 166 may be arranged to account for different size connectorplates 72.

Now referring to FIGS. 17-23, the structure and operation of the binassembly 86 in conjunction with the robotic arm 85 and presses 71A, 71Bwill be discussed in more detail. Bin assembly 86 comprises a baseportion 164 supporting a plurality of bins 166 thereon. Bins 166 includea bottom tray 168 having a rear portion 170, a central column 172 havinga central columnar cavity 174 with retention bars 176 for maintaining astack of connector plates 72 therein, and a front tray portion 178. Thefront tray portion 178 is sized to fit two or more connector plates 72therein. In one embodiment, the bin assembly 86 includes aninterconnecting rail 165 that extends around an upper perimeter of thebin assembly 86 and interconnects the plurality of bins at an upperportion of the bins.

In addition, to enable the bin assembly 86 to hold a large number ofconnector plates 72, yet make a small number of connector plates 72available for simple pick up by the robotic arm 85, the bin assembly 86includes a pushing assembly 180 for making two or more connector plates72 readily available in the front tray portion 178 of a bin 166 for easypickup of the connector plates 72 by the magnet 88 of the robotic arm85. As shown in FIGS. 19-23, pushing assembly 180 includes a pneumaticcylinder 182 (that is disposed between the bottom tray 168 and the baseportion 164), a piston 184, and an engagement member 186.

The pneumatic cylinder 182 is operably connected to an actuatingmechanism 188 disposed at the front tray portion 178 by two or morelines 190. As shown in FIG. 19, the pneumatic cylinder 182 may be of adouble acting cylinder type, having two ports (not shown): one foroutstroke and one for instroke of the piston 184. As shown in FIGS.20-21, the actuating mechanism 188 includes a push-button 192 or likestructure that, when contacted or otherwise activated, actuates a twoway valve (not shown) as is known in the art for allowing air into oneof two or more ports to move the piston 184 that is in contact orconnected to the engagement member 186 in a forward or backwarddirection. The backward or forward movement of the piston 184 in turncauses backward or forward movement of the engagement member 186.

In addition, as shown in FIG. 19, in one embodiment, the rear portion170 of the bottom tray 168 of bin 164 includes a longitudinal slot 194extending from a point adjacent an end of the rear portion 170 towardthe front tray portion 178. The engagement member 186 is slidablymounted within the longitudinal slot 194 and moves forward and backwardwithin the longitudinal slot 194 of the rear portion 170 of the bin 166to push two or more connector plates 72 from the central column 172 tothe front cavity 178 of the front tray portion 178. For this reason, inone embodiment, the engagement member 186 includes a top extent 196 anda front face portion 198. The top extent 196 is sufficiently long suchthat when the engagement member 186 pushes two or more plates 72 towardsthe front tray portion 178 of the bin 166, the remaining connectorplates 72 in the central column do not tilt or otherwise impede themovement of the two or more bottommost connector plates 72 being pushedinto the front tray portion 178.

When the controller 30 generates a signal indicative of an instructionfor the robotic arm 85 to retrieve a connector plate 72 from the platebin 86, robotic arm 85 first triggers the actuating mechanism 188 of apredetermined compartment of the plate bin 86 by contacting push-button192 for a sufficient time so as to activate the actuating mechanism 188.As a result of activation of the actuating mechanism 188, air may bedelivered to one of the two ports from a suitable compressed air sourcethrough air lines 190 to move the piston 184 in a forward direction.Since the piston 184 is secured to the engagement member 186, the piston184 will cause the engagement member 186 to move from its restingposition in a forward direction shown by arrow C in FIG. 20 to push twoor more of the bottommost connector plates 72 from the central column172 into the front tray portion 178. Thereafter, air will enter into theother of the two ports to allow the piston 184, and thus the engagementmember 186, to move back to a resting position. This process can berepeated each time two or more connector plates 72 are required forsecuring cord members 12 to web members 11A and 11B.

Presentation of Web Members for Assembly of Truss

Third station 16 includes an automated system 200 for presenting andpositioning the web members 12 relative to the cord members 11A, 11B onthe assembly table 20 in order from left to right, or from right toleft. As shown in FIGS. 24-26, the automated system 200 for presentingweb members 12 includes a conveyor 19B, a web presenter 90, and verticalposts 106 having laser sensors 107, 108 disposed in front of theconveyor 19B.

The web presenter 90, shown in FIGS. 24-26, may be a robotic arm that isequipped with a programmable controller to identify which member andtruss are located on the web assembly table 20, and the precise locationthereof. One suitable source for a robotic arm 90 of the type describedherein, which may be modified as desired, is the Fanuc Robot R-2000 iBrobotic arm.

With respect to FIG. 24 particularly, the web presenter 90 isillustrated grasping a web member 12 off of the conveyor 19B of thesecond station 15. The web member 12 cut by second saw system 18 will bepicked up by the web presenter 90, which may be a robotic arm, and laterpresented on the assembly table 20 for pickup by a main robotic arm 101for placement of the web member 12 within cord members 11A, 11B of acorresponding truss 10. The movement of the web presenter 90 iscontrolled in part by a controller that is operatively connected withthe web presenter (robotic arm) 90.

The second saw system 18 is linked with a controller 29 and isprogrammed to cut the web members 12 in the order in which the webmembers 12 are to be attached to the cord members 11A, 11B. The cut webmembers 12 exit a cutting zone of the second saw system 18 onto thelinear conveyor 19B, which transports the web members 12 down theconveyor 19B. The system 18 includes a sensor 94 positioned toward anend of conveyor 19B. The sensor 94 detects the presence of a web member12 on the conveyor 19B when a web member 12 reaches a predetermineddistance from the sensor 94 or end of the conveyor 19B. When a webmember 12 is detected a predetermined distance from the end of theconveyor 19B, the sensor 94 generates a signal indicative of thepresence of a web member 12, which signal is received by the sawcontroller 29. The saw controller 29 is in communication with the motorand belt assembly 38 and signals the motor and belt assembly 38 to stop.At the same time, the sensor 94 conveys a signal to controller 30 or 104for the robotic arm 90 to pick up the web member

The controller 31 is programmed to identify the particular web member 12including the length of the web member 12. As explained above, each ofthe controllers is programmed to include a database that includes datarepresentative and associated with each web member 12, including thedimensions of the web members 12 or cord members 11A, 11B, and the orderin which the components are cut, staged and assembled. Accordingly, asthe web members 12 are cut, staged and assembled, the controller 31counts or identifies each web member 12 as it is staged and presentedfor assembly.

When the sensor 94 detects the web member 12, a signal is generated andsent to the controller 31. In tun, when the controller 31 receives thesignal from the sensor 94, the controller 31 identifies the web member12 including the length of the web member 12. The controller 31 is ableto calculate the rate of speed the web member 12 is traveling on theconveyor 19B. Based on this calculation the controller 31, also havingdata relative to the length of the web member 12, determines the time atwhich the web presenter 90 will be activated to verify the identity ofthe web member 12, adjust a position of the web member if necessary, andpresent the web member 12 to the assembly table 20 for pickup by therobotic arm 101. The web member 12 is positioned on assembly table 20such that the robotic arm 101 will pick up the web member 12 at apredetermined location of the web member 12 as will be discussed indetail below.

Prior to the robotic arm 101 engaging the web member 12, the webpresenter 90 may perform functions that assure the web member 12 ispositioned at the appropriate coordinates for presentation to therobotic arm 101. In an embodiment, as shown in FIGS. 24-33, verticalposts 106 that support laser sensors 107 characterize dimensions of theweb member 12 as will be set forth below. Posts 106 include slots 109therein and a receiving block 112 having an opening therein forreceiving respective ends of the web member 12 and for detection of theweb member 12 by the laser sensors 107, 108.

With respect to FIGS. 24-33, the measurement and positioning/centeringof a web member 12 on the assembly table 20 for pickup by the roboticarm 101 is illustrated. The controller 31 has data relative to thelength of the web member 12 and determines the time at which the webpresenter 90 must be activated to first verify the presence of aparticular web member 12, identify a staple center of the web member,and present the web member 12 to the assembly table 20 for pickup byrobotic arm 101.

First, the web presenter 90 grasps the web member 12 at or adjacent acenter of the web member as shown in FIG. 24 using a suction platen 202.Second, as shown in FIG. 25, and more closely in FIGS. 28-29, the webpresenter 90 (not shown in FIGS. 27-33 for purposes of clarity) is moveda particular distance to the left such that the leftmost point or firstleading edge 204 of the web member 12 can be detected by the leftmostsensor 107 on the left vertical post 106. The controller 31 monitors themovement of the robotic arm relative to the sensor 107. For example,when the servomotor 104 moves the web presenter 90 to the left, itgenerates one or more signals to the controller 31 representative of thedistance that the robotic arm has moved. Thereafter, as shown in FIG.30, the web presenter 90 continues to move the web member 12 leftwardand stops when the sensor 107 senses a second leading edge 206 of a leftside 205 of the web member 12. Again, once the second leading edge 206is detected, the controller 31 determines the distance the robotic armhas traveled.

Once the two leading edges 204, 206 for the left side of the board havebeen detected, the controller 31 causes the web presenter 90 to moverightward to likewise determine a first leading edge 208 and secondleading edge 210 on the opposed right side 211 of the board. As shown inFIGS. 31-32, a first leading edge 208 of a right side of the web memberis detected by the rightmost sensor 208. The controller 31 monitors themovement and position/location of the web presenter (robotic arm) 90relative to the sensor 108. Thereafter, as shown in FIG. 33, the webpresenter (robotic arm) 90 moves rightward to determine the secondleading edge 210 of the right side of the particular web member 12.Again, one the second leading edge 210 is detected, the servomotor 104generates one or more signals to the controller 31 representative of thedistance that the robotic arm has moved.

From the information gathered by the sensors 107, 108, the controller 31can verify that a length 212 of the web member 12 between the firstleading edges 204, 208 and a length 214 between the second leadingsecond leading edges 206, 210 match the data for the web member 12 inthe controller 31. If so, the identity and length of a particular webmember 12 is verified. If the gathered data does not verify the identityof the measured web member 12, a signal can be emitted from thecontroller to indicate that the controller 31 could not identify the webmember at the front of the conveyor and appropriate action may be taken.For example, if the board does not have the proper dimensions, anoperator stops the system to manually inspect the board. If the operatorconfirms that the dimensions are incorrect, the operator may manuallycut the board to the correct dimensions. In addition, the operator mayneed to inspect other boards to determine the system 200 is cutting andpresenting the boards in the proper order. Further, it is contemplatedthat depending on the orientation and cut of the board, some web membersmay not have more than one leading edge, which is detectable by thesensors 107, 108. In such case, only the first leading edge on each sideof the board will be measured and that data utilized to determine theidentity and length of the particular web member.

In one embodiment, the web presenter 90, after verifying the identity ofthe web member, places the web member 12 on the assembly table 20 asindicated in FIG. 26 by grasping the web member at a center 216 of thelength 212 between the confirmed two leading edges 204, 208 of the webmember 12. In another embodiment, however, instead of placing the webmember 12 on the assembly table 20 such that robotic arm 101 will pickup the web member at the center 216 of the web member 12, the controller31 will cause the arm of the web presenter 90 to shift left or right toadjust the position of the web member 12 on the table 20 such that therobotic arm 101 will pick up the web member 12 at a staple center 218 ofthe web member. The staple center 218 may be defined as a length betweena first staple location 220 and a second staple location 222 (where theweb members 12 will be stapled to adjacent cord members 11A, 11B).

To illustrate an exemplary board, FIG. 34 shows the center 216 betweenthe first leading edges 204, 208 of a web member 12, a center 224between the second leading edges 206, 210 of the web member 12, and thestaple center 218 between the first and second staple locations 220,222. In the embodiment described above, the web presenter 90 willpresent the web member 12 on the assembly table 20 at a location suchthat the robotic arm 101 will pick up the web member 12 at the staplecenter 218.

To further illustrate the above apparatus, system 200, and method forverifying the identity of a particular web member 12 and adjusting theposition of the web member on the assembly table, a particular exampleis provided. In this example, the distance between the two sensors is130 inches, for example. When the web presenter 90 grasps the web member12, the web presenter 90 is generally positioned to grasp the web member12 using suction platen 202 or the like at an approximate center of theboard, i.e., a centerpoint (65 inches) between the two sensors. However,in this example, the web member 12 is grasped by the web presenter onthe conveyor 19B slightly off center at for example 1 inch to the leftof a center 216 between the leading edges 204, 208 of the board. Thus,there are 64 inches to reach left sensor 107. In this example also, theweb member 12, prior to verification, is believed by the controller 31to be a web member having a total length of 40 inches.

First, the controller 31 causes the web presenter 90 to move leftward adistance of 46 (65-19) inches before the sensor detects a first leadingedge 204 of the web member. Thereafter, the web presenter 90 willcontinue to move the web member 12 leftward until the second leadingedge 206 is detected, which may be another couple of inches, forexample. Thus, when the second leading edge 206 is detected, the webpresenter 90 will have moved a total of 48 inches to the left.Thereafter, the controller 31 will generate a signal to cause the webpresenter 90 to move to the right.

Since the web presenter 90 grasped the web member 12 slightly offcenter, the web presenter 90 will continue to move the web member 12rightward until the right sensor 108 detects the first right leadingedge 208 of the web member 12, which if the board is a 40 inch board,will be at 92 inches (65 inches-21 inches (half the board plus one inchoff center) plus 48 inches. Thereafter, the web presenter 90 willfurther move the web member 12 rightward such that the second leadingedge 210 is detected, which may be, for example, another six inches tothe right. The controller 31 now has all the information necessary toconfirm the identity of the web member 12. When the identity of the webmember 12 is verified, the controller 31 can also identify the fact thatthe web presenter 90 has grasped the board one inch off-center to theleft and account for the same.

Having the data stored therein, the web presenter 90 will now compensatefor the staple center 218 of the web member 12. The location of thestaple center 218 is predetermined and the information is stored withthe controller 31. If for example, the staple center 218 is two inchesfrom the center 216, the web presenter 90, after compensating for theone inch off-center noted above, will move the web member 12 to the lefttwo inches when placing the web member 12 on the assembly table 20 asshown in FIG. 26 for pickup by the robotic arm 101.

Referring now to FIG. 36, the robotic arm 101 is shown as comprising afirst lever arm 224 pivotally connected to a second lever arm 226. At anend of the second lever arm 226, there is mounted a movable clampingassembly and a stapling assembly mounted on a frame 234. The movableclamping assembly is shown as comprising two clamping devices 228mounted on a frame 234. The stapling assembly is shown as including twostaple guns 230 mounted on the frame 234. Of course, any number ofclamping devices or stapling devices may be provided. One suitablesource for a base model robotic arm 101 of the type described herein,which may be modified to include staple guns, clamping devices as isnecessary, is the Fanuc Robot M-900iA-260L robotic arm.

Alternatively, instead of temporarily and/or permanently stapling two ormore adjacent truss components together, such as cord members to cordmembers, web members to cord members, or web members to web members, thetwo or more truss components may be manually or automatically andtemporarily and/or permanently secured to one another by applying anadhesive or taping the truss components together. If an automatedadhesive dispenser or tape applicator is utilized, in one embodiment,the adhesive dispenser or tape applicator may be positioned at the samelocation on the robotic arm 101 as the staple guns 230 described above.Suitable adhesives, include, but are not limited to fast drying hot meltadhesives. If tape is used to secure two or more truss componentstogether, the tape may be a double-sided foam tape available from 3M,for example. Alternatively, the adhesive or tape may be any othersuitable adhesive or tape known in the art. Further, any suitableautomated adhesive dispensing or tape application device known in theart may be utilized.

In one embodiment, the clamping devices 228 and staple guns 230 mountedon the second lever arm 226 are movable as a unit on a servomotor driventrack 232, which is disposed on a base portion of the frame 234. Theservomotor driven track 232 enables the lateral movement of the stapleguns 230 and clamping devices 228 on the track 232 such that theclamping devices 228 can grasp a web member 12 from a position on theassembly table 20 adjacent the web presenter 90, place the web member 12at its suitable position between cord members 11A, 11B, and the stapleguns 230 can provide a staple to the truss 10 to at least temporarilysecure a web member 12 to a cord member 11A, 11B. In one embodiment, thestaple guns 230 are driven by contact such that when either of thestaple guns 230 contact a web member 12 or cord member 11A, 11B, thestaple gun or guns 230 automatically trigger to drive a staple into theweb member 12 or cord member 11A, 11B.

In one embodiment, the clamping devices 228 include a first plate member236 and a second plate member 238. The second plate member 238 ismovable inward or outward relative to the first plate member 236 on apiston 240. In one embodiment, the second plate member 238 is movableinward or outward by way of a pneumatic cylinder 242 of the type setforth with respect to the pneumatic cylinder 186 above. The pneumaticcylinder may be of a double acting cylinder type, having two ports toallow air in, one for outstroke and one for instroke and the piston 240.The movement of the piston 240 allows the second plate member 238 tomove inward or outward with respect to the first plate member 236 inresponse to any communication from the controller 31 that there is a webmember 12 for the clamping device 228 to grab or release.

Once the web member 12 on the assembly table 20, the robotic arm 101will pick up the web member 12 at the staple center 218 and willposition the web member 12 for attachment to corresponding cord members.As shown in FIG. 35, for example, the robotic arm 101 is shown placing aweb member 12 in position for attachment to the cord members 11A, 11B.As illustrated, the bottom right corner of cord members 11A, 11B hasalready been advanced on the table 20 to a position where the press 71Bwill move into position to stamp connector plates 72 at the corner asdescribed above. In addition, the cord members 11A, 11B are positionedon the table 20 to receive the first web member 12 at location on thetable 20 between the roller guides 42A, 42B.

The robotic arm 101 may be programmed to distinguish web members 12 fromone another. The robotic arm 101 is programmed to retrieve each webmember 12 at a particular location having an x,y,z coordinates relativeto the end of the robotic am 101 and ground. In one embodiment, the webpresenter 90 positions the staple center 218 of each web member 12 atthat location. Similarly, the robotic arm 101 is programmed to positionthe staple center 218 of the web member at the above-mentionedpredetermined positions which have x,y,z coordinates relative to the endof the robotic arm 101 and the ground. The controller 30 and componentsof the assembly table (clamping devices, roller guides etc.) areprogrammed to advance the truss 10 on table 20 to a position so the webmember 12 fits between and abuts the inside edges of the cord members11A, 11B.

When the robotic arm 101 has retrieved the web member 12 as describedabove, the controller 30 or 104 generates one or more signals responsiveto which the robotic arm 101 moves on a gantry 120 and/or rotates tograb the web member 12. The robotic am 101 then places the staple center218 (not shown here) of web member 12 at a first predetermined locationthat so the ends of the web member 12 are displaced to the left of thecord members 11A, 11B. The robotic arm 101 then moves the center 218 ofthe web member 12 to the right so that each end of the web member 12abuts an inside edge of a respective cord member 11A, 11B as shown inFIG. 35.

The controller 30 or 104 is in electrical communication with a processorof the robotic arm 101, to determine when the web member 12 isappropriately positioned for attachment to the cord members 11A, 11B. Atthat time, the controller 30 or 104 generates one or more signals,responsive to which staple guns 230A, 230B move across the table 20 tostaple the web member 12 to the cord members 11A, 11B. The controller 30or 104 monitors the movement of a servo-driver (not shown) connected tothe staple gun 230A or 230B so the controller 30 is able to determinewhen the staple guns 230A, 230B (and the presses 71A, 71B describedabove) return to a home position, so the truss 10 may be advanced on thetable 20.

Typically, the truss 10 is thereafter advanced on the table 20 asufficient distance so the points at which the web member 12 abut theinside edges of the cord members 11A, 11B, are aligned with the presses71A, 71B. In this manner, the presses 71A, 71B, responsive to one ormore signals from the main controller 30, move on I-beam 144 to pressconnector plates 72 onto the truss, thereby securing the web member 12to the cord members 11A, 11B as described previously herein. As thepresses 71A, 71B are moving and/or stamping the connector plates 72 onthe truss 10, the robotic arm 101 is retrieving a second web member 12and placing it in position relative to the cord members 11A, 11B forassembly of the truss 10. These steps are repeated for all the webmembers 12 for a particular truss until the truss 10 is fully assembled.

As shown in FIG. 2, the assembled truss 10 may also be advanced on theassembly table 20 a sufficient distance by rollers 36 to a main press 39where larger connected plates may be pressed on portions of the truss asneeded. As shown in FIG. 37, main press 39 includes an upper platen 244and a lower platen 246 that are supported on opposed beams 248 supportedby a large frame 250. The beams 248 are capable of being raised orlowered toward one another by a hydraulic cylinder as is known in theart, thereby allowing the upper platen 244 and the lower platen 246 tomove toward one another with sufficient force to press a relativelylarge connector plate (not shown) on the truss components.

In addition, the main press 39 may include one or more pneumaticcylinders, including one of the type described with respect to presses71A, 71B to separate any two connector plates 72 when the two connectorplates are placed on a lower platen 246. Further, the pneumatic cylindermay aid in retracting the platens 244, 246 after the connector plates 72are pressed onto a particular truss 10. In one embodiment, the pneumaticcylinder is embedded in the upper platen 244 and the upper platenincludes a magnet (not shown) to aid separating any two connector platesthat are placed on the lower platen 246.

In one embodiment, the clearance space 252 between the upper platen 244and the lower platen 246 when the press 39 is in an idle position isrelatively small, i.e., about three inches. In this way, when theplatens 244, 246 are moved toward one another to press a large connectorplate on a portion of the truss 10, the truss and/or connector plate isnot bent, crushed, twisted, or otherwise damaged.

The present invention, in various embodiments, includes components,methods, processes, systems and/or apparatus substantially as depictedand described herein, including various embodiments, subcombinations,and subsets thereof. Those of skill in the art will understand how tomake and use the present invention after understanding the presentdisclosure. The present invention, in various embodiments, includesproviding devices and processes in the absence of items not depictedand/or described herein or in various embodiments hereof, including inthe absence of such items as may have been used in previous devices orprocesses, e.g., for improving performance, achieving ease and/orreducing cost of implementation.

The foregoing discussion of the invention has been presented forpurposes of illustration and description. The foregoing is not intendedto limit the invention to the form or forms disclosed herein. In theforegoing Detailed Description for example, various features of theinvention are grouped together in one or more embodiments for thepurpose of streamlining the disclosure. This method of disclosure is notto be interpreted as reflecting an intention that the claimed inventionrequires more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive aspects lie in less than allfeatures of a single foregoing disclosed embodiment. Thus, the followingclaims are hereby incorporated into this Detailed Description, with eachclaim standing on its own as a separate preferred embodiment of theinvention.

Moreover, though the description of the invention has includeddescription of one or more embodiments and certain variations andmodifications, other variations and modifications are within the scopeof the invention, e.g., as may be within the skill and knowledge ofthose in the art, after understanding the present disclosure. It isintended to obtain rights which include alternative embodiments to theextent permitted, including alternate, interchangeable and/or equivalentstructures, functions, ranges or steps to those claimed, whether or notsuch alternate, interchangeable and/or equivalent structures, functions,ranges or steps are disclosed herein, and without intending to publiclydedicate any patentable subject matter.

1. A system for the automated assembly of a truss, comprising: a firststation having one or more automated saw systems for cutting lumber intotruss components, including a plurality cord members and web members,wherein the automated saw systems comprise a controller programmed witha specification to cut the cord members and web members in apredetermined order representative of an order in which the componentsare assemble relative to one another; a second station, in conveyorcommunication with the first station, wherein the cord members aresupported and positioned relative to one another form a perimeter of thetruss, and wherein the second station comprises a controller that isprogrammed to position the cord members relative to one another inaccordance with the specification; a third station, in conveyorcommunication with the first station, that supports the cut web memberswhich are positioned relative to one another in a predetermined order ofattachment to the cord members and in accordance with the specification;means, at the second station or third station and responsive to acontroller, for engaging a web member at the third station andtransferring the web member to the second station and positioning theweb member relative to the cord members for attachment; and, means, atthe second station and responsive to a controller, for securing two ormore truss components in accordance with the specification.
 2. Thesystem of claim 1, wherein the second station further comprises anassembly table and a plurality of grasping members for grasping cordmembers and for orienting the cord members relative to one another onthe assembly table, and wherein the grasping members are laterallymovable on the assembly table for orienting a cord member at an anglerelative to an adjacent cord member.
 3. The system of claim 2, whereinthe grasping members comprise a register for engaging an inner portionof the cord member and a plurality of rollers for engaging an outerportion of a cord member.
 4. The system of claim 2, wherein the secondstation further comprises a plurality of passive rollers for conveyingcord members in a downstream direction along the assembly table.
 5. Thesystem of claim 2, wherein the grasping members further comprise a pivotarm, wherein the pivot arm is movable from a first position where theregister and plurality of rollers engage a cord member to a secondposition where the register and plurality of rollers do not engage thecord member.
 6. The system of claim 1, wherein the third stationcomprises: a robotic arm for grasping a cut web member conveyed to thethird station; and means for verifying the dimensions of the cut webmember; and a controller for comparing first stored values for thedimensions of the cut web member with second values obtained from themeans for verifying.
 7. The system of claim 1, wherein the means forsecuring comprises a robotic arm mounted for lateral movement over aportion of an assembly table of the second station or third station,wherein the robotic arm comprises one or more staple guns and one ormore clamping members for orienting and securing two or more trusscomponents.
 8. The system of claim 1, wherein the means for securingcomprises means for applying adhesive to a junction of two or more trusscomponents.
 9. The system of claim 1, further comprising means foraffixing a connector plate to the two or more truss components, whereinthe means for affixing a connector plate comprises: a plurality of binsfor storing a plurality of connector plates; a robotic arm for graspingtwo or more connector plates from one of the plurality of bins; a pressfor affixing the two or more connector plates comprising upper and lowermagnetized platens mounted for up and down movement relative to oneanother, wherein the press is mounted for lateral movement over anassembly table of the second or third station for affixing the two ormore connector plates at a junction of the two or more truss components.10. The system of claim 1, wherein the bin assembly comprises: a base; aplurality of bins mounted on the base, wherein the plurality of binscomprise a tray and a connector plate storage compartment for storing aplurality of connector plates; and means, within a bin, for dispensingtwo or more connector plates from the connector plate storagecompartment to a front portion of the tray.
 11. The system of claim 10,wherein the means for dispensing two or more connector plates comprises:an engagement member mounted for lateral movement on the tray; and anactuating mechanism for causing movement of the engagement member towardthe connector plate storage compartment when activated.